I tried to search to find answers, but seeing as I am in the middle of doing the doo I'll just ask. Sorry if its redundant. (I'm asking on this thread because I find it better than any of the "KLR mod" threads. Good job Gas Guy!!)

I am upgrading to a torsion spring. I removed the stock extension spring without removing the inner case. Since the torsion spring goes outside the inner case, do I still need to remove it for anything?
Also, the "lever" that the stock extension spring was connected to is just floating on the shaft. Is this correct, I have basically just obsoleted that part and it remains on the shaft?

So basically, am I ok not removing the inner case if I've removed the spring? Thanks in advance. Maybe I can wrap this up tonight and move on to putting on my new chain.

BTW my stock spring had plenty of tension and travel, I almost closed it back up without changing it.

The factory spring lever does stay in place as it acts as a spacer to keep proper endplay.

You should be good to go, just try to catch all the debris as you drill the hole, keep it out of the engine.

I didn't pull my inner cover either when I had to redrill the hole and install a new spring.

The factory spring lever does stay in place as it acts as a spacer to keep proper endplay.
You should be good to go, just try to catch all the debris as you drill the hole, keep it out of the engine.
I didn't pull my inner cover either when I had to redrill the hole and install a new spring.

Did you need the Deep Hole spacer ??

Hey thanks for the response! No Deep Hole Spacer needed.

I will drill the hole and start assembly. Just wanted to make sure I wasn't skipping something critical by taking a short cut.

Thanks for all your detailed projects too, every time I read them it makes me want to go tinker on stuff in the garage

I've been kind of busy lately, plus hunting down parts, and playing with some shock ideas.
Been putting together some fittings and such, and mock up mounting of a reservoir.
Its still in the works but here is a teaser picture.

I've not heard much about Fox shocks. What's the latest skinny on them?
I know for the last 15 years seems they've been more involved with bicycles than motorcycles.

Yeah, unfortunatly Fox got out of the motorcycle shock business, to a lot of peoples dismay.

Don't despair ... because (as I'm sure you know) several other companies are now making shocks for the KLR. I think Ohlins might have something with their latest generation of low cost shocks.

Also ... I'd bet there are one or two shock guys who can rebuild your stock KYB and make it magical. Not sure, but Cogent Dynamics does a number on the DR650 KYB unit and turns it into a Rolls Royce. Not cheap ... but cheaper than an aftermarket shock. Perhaps Cogent can do the KLR shock as well .. if they don't already?

Don't despair ... because (as I'm sure you know) several other companies are now making shocks for the KLR. I think Ohlins might have something with their latest generation of low cost shocks.

Also ... I'd bet there are one or two shock guys who can rebuild your stock KYB and make it magical. Not sure, but Cogent Dynamics does a number on the DR650 KYB unit and turns it into a Rolls Royce. Not cheap ... but cheaper than an aftermarket shock. Perhaps Cogent can do the KLR shock as well .. if they don't already?

If I ever spend the money on a high dollar shock, I would have Penske build it for me.

I had them on my GSA and they are impressive and you get a full service and parts manual with it, and are advertised as owner rebuildable.
You can call them up and order parts or ask them tech questions and they are glad to help you.

The powersport shock division of Penske is called Custom Axis.

They will build what ever you want for anything.You can even print off a order form from there website and fill in all the dimensions.

My buddy still has his on his GSA, and he has about 60,000 miles on his Penske shocks.We have gone 25,000 miles on the fluid and it was like new when we changed it.

Also, Penske offers a Quad Ring seal for the shaft seal if you want it instead of the normal O-Ring.We went to them because they last much longer before leaking.

We also put these Fox reservoirs on his Penske shocks front and rear on his GSA and he really likes them